Apparatus for Producing a Hook-and-Loop Fastener Connector via an Injection Molding Method

ABSTRACT

The invention relates to an apparatus for producing a hook-and-loop fastener connector ( 18 ) via an injection molding method, which comprises: an injection mold ( 11 ) having a plurality of first and second mold halves ( 1;2 ), wherein each first mold half ( 1 ) exhibits a plurality of first cavities ( 3 ) in a first surface ( 4 ) and each second mold half ( 2 ) exhibits a plurality of second cavities ( 5  ) in a second surface ( 6 ), and the first and second surfaces ( 4;6 ) face each other and contact such that the first and second cavity ( 3; 5 ) together form an entire cavity in hook form, wherein the hook form ( 7 ) exhibits a hook foot ( 8 ) and a hook head ( 9 ), and the hook foot ( 8 ) and hook head ( 9 ) are arranged within one plane, wherein the hook foot ( 8 ) is formed at least by the first cavity ( 3 ) and the hook head ( 9 ) is formed at least by the second cavity ( 5 ), wherein the injection mold ( 11 ) has a longitudinal axis ( 12 ) along which the second mold halves ( 2 ) are displaceable in relation to the first mold halves ( 1 ), characterized in that the plane ( 10 ) and the longitudinal axis ( 12 ) are angled to one another.

The invention relates to an apparatus for producing a hook-and-loopfastener connector via injection molding, an injection molding methodfor producing a hook-and-loop fastener connector, and a hook-and-loopfastener connector.

In a hook-and-loop fastener, a hook-and-loop fastener connector with aplurality of hooks makes contact with a loop element or respectivelypile portion having loops or fibers, whereby the hooks interlock in theloops/fibers. A reversibly detachable connection is thereby establishedbetween the hook-and-loop fastener connector and the loop element.

This connection can be disengaged again by pulling the loop element fromthe hook-and-loop fastener connector. This reversibly detachableconnection is used in many fields to releasably fasten articles orcomponents. In motor vehicles, for example, floor mats on the floor ofthe vehicle are secured against slipping or raising by means of ahook-and-loop connection in that fastening means having a hook-and-loopfastener connector are anchored to the interior floor of the vehiclewhich, upon contact with a pile portion of a floor mat, enables thefloor mat to be reversibly fixed to the vehicle floor.

A hook-and-loop connection in the form of a fastening device for a motorvehicle floor mat is thereby conventionally provided by a base bodyhaving a plurality of hooks being glued to an e.g. circular substrate bymeans of chemical or thermal adhesive bonds, for example solvent-basedadhesives or hot-melt adhesives, and this substrate being fixed to thefloor of the vehicle interior via fastening means. Apart from theenvironmental impact of solvent-based substances, neither the chemicalnor the thermal adhesive bonds are satisfactory. Because there is therisk of the base body containing the plurality of hooks disengaging fromthe substrate when the temperature and/or the relative air humidityinside the vehicle is too high. There is furthermore also the risk ofdetachment after the floor mat has been in use for a long time and thebase body with the plurality of hooks detaching from the substrate dueto mechanical stress such as, for example, the foot movements of personswithin the vehicle.

Alternatives to the above-described conventional bonding of the basebody with the plurality of hooks onto a substrate are also known in theprior art.

WO 2014/191089 A1 discloses an injection mold and process in which afastening part with adhesive and/or hooking elements forming a componentof a contact fastener is produced and introduced into the injection moldas an insert part in a first step, and a substrate which connects to theinsert part is formed using a foamed plastic material in a second step.Meaning that the insert part and the substrate of WO 2014/191089 are notformed as one piece.

DE 10 2009 054 896 A1 discloses a tool for producing a hook-and-loopdisk via injection molding in which the hooks are formed together withthe hook-and-loop disk in one step. In the thusly obtained hook-and-loopdisk, the hooks are arranged vertically on the disk-shaped base plate ofthe hook-and-loop disk. Due to this vertical arrangement, the hooks areformed with a hook head of approximately half the cross section of thehook foot as the hook head can only be formed in the second tool elementof the tool because otherwise the first and second tool parts of thetool would not be displaceable against each other after the injectionmolding of the hook-and-loop disk.

The task of the present invention is that of providing an apparatus, amethod as well as a hook-and-loop fastener connector which enables easyremoval or expulsion respectively of the hooks of an injection moldedhook-and-loop fastener connector within an injection mold. A furthertask of the present invention is that of providing a hook-and-loopfastener connector which ensures a particularly stable hook-and-loopconnection to a pile portion.

This task is solved by an apparatus for producing a hook-and-loopfastener connector via an injection molding method according to claim 1,an injection molding method for producing a hook-and-loop fastenerconnector according to claim 9, and a hook-and-loop fastener connectoraccording to claim 12.

This task is in particular solved by an apparatus for producing ahook-and-loop fastener connector via an injection molding method, whichcomprises:

An injection mold having a plurality of first and second mold halves,wherein each first mold half exhibits a plurality of first cavities in afirst surface and each second mold half exhibits a plurality of secondcavities in a second surface, and the first and second surfaces faceeach other and contact such that the first and second cavity togetherform an entire cavity in hook form,

wherein the hook form exhibits a hook foot and a hook head, and the hookfoot and hook head are arranged within one plane, wherein the hook footis formed at least by the first cavity and the hook head is formed atleast by the second cavity,

wherein the injection mold has a longitudinal axis along which thesecond mold halves are displaceable in relation to the first moldhalves,

characterized in that the plane and the longitudinal axis are angled toone another.

The idea on which the invention is based is that of the first and secondmold halves being formed in such a way that the plane within which thehook foot and the hook head of the hook form are arranged and thelongitudinal axis of the injection mold are angled to one another. Thisfirstly enables a hook injection molded in the injection mold to beeasily removed/ejected from the first and second mold halves bydisplacing the second mold half relative to the first mold half alongthe longitudinal axis of the injection mold, and enables advantageousdimensioning to be provided to the hook head as well as an advantageousangled arrangement of the injection molded hooks on the hook-and-loopfastener connector.

The following will mostly make use of the singular form of the terms“hook form” and/or “hook,” “mold half” and “surface,” whereby one, orrespectively one of the plurality, of “hook (forms),” “mold halves” or“surfaces” of the inventive apparatus is thereby meant as an example.

To be understood by the term “hook-and-loop fastener connector” as usedherein is an object having a plurality of hooks, its hooks interlockingwith a loop element or respectively pile portion exhibiting loops/fibersupon contact. A reversibly detachable connection is thereby establishedbetween the hook-and-loop fastener connector and the loop element.

To be understood by the term “hook head” as used herein is a structurewhich enables interlocking with a felt-like or fiber-like structure of aloop element or pile portion. Such a structure can be a curved orrespectively round structure, for example a semicircular structure or astructure constituting less than a semicircle, e.g. a ⅓ circle, or morethan a semicircle, e.g. a ⅝ circle. Alternatively, this structure canalso exhibit an angled or respectively angular form such as, forexample, an inverted V shape or an angular inverted U shape.Combinations of the aforementioned structures are also possible, e.g.inverted V or U shapes with circular rounded corners, or curved orrespectively round structures complemented by linear elements such as,for example, a rounded inverted U shape. Preferentially, the hook headis ⅓ to ⅝ circular in shape. The hook forms can also be configured asdouble hooks, which is obtained by forming two hook heads on one hookfoot, these hook feet pointing in 180° opposite directions.

To be understood by the term “hook foot” as used herein is a structurewhich connects the “hook head” to a base body, e.g. a base plate, of thehook-and-loop fastener connector. The “hook foot” is preferentially ofstraight structure. With a circularly curved hook head, the hook headbegins where the curvature of the hook head begins. With anangled/angular form to the hook head, the hook foot ends and the hookhead begins at a point where an imaginary line from the end of the hookhead perpendicularly intersects the hook foot. However, the separationbetween hook head and hook foot by way of the above-described point ispurely schematic. Because in three-dimensional form, part of the hookfoot can fall below or exceed the height of this schematic separationpoint along the longitudinal direction of the hook foot, for examplewhen the hook head is formed in the second cavity of the second moldhalf and the hook foot is formed in the first cavity of the first moldhalf and the second cavity of the second mold half.

To be understood by the term “longitudinal axis” of the injection moldas used herein is an axis along which the second mold halves aredisplaceable in relation to the first mold halves. Meaning that thefirst and second mold halves can be displaced on or parallel to thelongitudinal axis of the injection mold. Preferably, the longitudinalaxis of the injection mold is perpendicular to a surface of theinjection mold which forms the side of a hook-and-loop fastenerconnector base plate on which the plurality of hooks is formed, wherebythis surface is preferably formed entirely or partially by the thirdsurfaces of the first mold halves and fourth surfaces of the second moldhalves described below.

In addition to the special injection mold with its first and second moldhalves, the apparatus comprises the usual devices of an injectionmolding device such as, for example, means for heating the plastic to beinjected into injection mold, injection runners for the injection moldin order to force molten plastic into the injection mold, and means forappropriately opening/closing the injection mold.

The plane in which the hook foot and the hook head of the hook form arearranged and the longitudinal axis of the injection mold are preferablyangled to each other at an angle of up to 40°, further preferentially 5°to 30°, and particularly preferentially 10° to 20°. This preferentialangling of the plane and longitudinal axis is advantageous because itenables more easily removing/ejecting the injection molded hooks fromthe first and second cavities and this choice of angle if necessary alsoenables the hook head of the hook form to be formed completely in thesecond cavity. The angles a specified in conjunction with the angledarrangement of the plane and the longitudinal axis to one another alsoinclude negative angles; i.e. angled −40° to each other, furtherpreferentially −5° to −30° to each other, and particularlypreferentially −10° to −20° to each other. Meaning that the hook formscan be formed in opposite directions within the first and second moldhalves, thus once at a positive angle and once at a negative angle.

It is preferential for the first and second surfaces of the plurality offirst and second mold halves to be arranged parallel to each other,further preferentially parallel to the longitudinal axis. This parallelarrangement enables the first and second mold halves to each beconfigured in the same way; i.e. making the configuration/production ofthe first and second mold halves easier compared to a non-parallelarrangement. It is particularly advantageous for the first and secondsurfaces of the plurality of first and second mold halves to be arrangedparallel to the longitudinal axis to one another. This enables both thefirst as well as the second mold half to be variably displaceableupwards or downwards in relation to one another along the longitudinalaxis.

Preferably the hook foot is formed by the first and second cavity, andthe hook head is formed by the second cavity. This has the advantage ofthe injection molded hook being easily removable, or demoldedrespectively, by the second mold half displacing relative to the firstmold half, since the hook head is formed completely in the secondcavity; i.e. displacement can press on the hook head, for example, inorder to easily remove or respectively demold the injection molded hook.Further advantageous with this embodiment is that by the hook head onlybeing formed in the second cavity, the hook head of the injection moldedhook cannot block the displacement of the first and second mold halvesrelative to one another.

The hook head preferably has a cross section or a cross-sectional areaequal to or greater than the cross section/cross-sectional area of thehook foot. This has the advantage of particularly stable injectionmolded hooks being able to be produced by means of the inventiveapparatus since the dimensioning of the hook head has a significantinfluence on the stability of the hooking connection of thehook-and-loop fastener connector to a pile portion. Because if the crosssection or cross-sectional area of the hook head is of smaller dimensionthan the hook foot, there is the risk that pulling on the pile portionwill result in the hook heads of the hooks of the hook-and-loop fastenerconnector at least partly tearing away, thereby weakening the hookingconnection.

To be understood by the term “injection mold” as used herein is anentire cavity in the form of a hook-and-loop fastener connector, whereinthe plurality of first and second mold halves, the plurality of hooks ofthe hook-and-loop fastener connector, as well as the surface form a basebody when the injection mold is injected with molten plastic. Theinjection mold has one or more injection runners enabling the injectionmold to be filled with molten plastic. The base body of thehook-and-loop fastener connector can in principle be of any shape;preferentially, the base body is formed in the shape of a base plate;i.e. a planar body having a certain thickness on which the plurality ofhooks are formed. The base body can optionally comprise fastening meanswhich allows the base body with the plurality of hooks to be fixed to afurther object. The “injection mold” can thus constitute an entirecavity which, in addition to the plurality of hooks formed by theplurality of first and second mold halves and the surface of the basebody on which the plurality of hooks are formed, also represents thefurther shape of the base body with optional fastening means such that ahook-and-loop fastener connector with a plurality of hooks and a basebody with optional fastening means can be formed in the injection moldin one piece.

The injection mold of the inventive apparatus is preferably designedsuch that the first mold half exhibits a third surface and the secondmold half exhibits a fourth surface, the third surface being adjacentthe first surface and the fourth surface being adjacent the secondsurface, whereby the third and fourth surface together form an openingconstituting the cross section of the lower end of the hook foot.Preferentially, this opening leads to a further cavity in the form of abase plate of the hook-and-loop fastener connector so that when theinjection mold is filled, a hook-and-loop fastener connector having aplurality of hooks formed on the base plate is obtained. This injectionmold configuration is advantageous in order to produce a hook-and-loopfastener connector having a base plate on which a plurality of hooks isformed.

The further cavity in the form of a base plate of the hook-and-loopfastener connector can further comprise a cavity having the form offastening means on a side opposite the third and fourth surfaces so thatwhen the injection mold is filled, a hook-and-loop fastener connectorhaving a plurality of hooks formed on the base plate is obtained,wherein the base plate is formed on the side of a fastening meansopposite the side with the plurality of hooks.

It is preferential for the third surface to be perpendicular to thefirst surface and the fourth surface to be perpendicular to the secondsurface. This enables advantageously easy displaceability of the firstand second mold halves relative to each other and thus also anadvantageous removing or respectively expelling from the injection mold.

The second mold halves are preferably displaceable in the direction ofthe further cavity in the form of a base plate of the hook-and-loopfastener connector while the first mold halves maintain their position.This enables a particularly advantageous removal/demolding. Because ifthe further cavity in the form of a base plate is opened on the sideopposite the first and second hook forms, the aforementioneddisplacement by the second mold halves can exert pressure on theinjection molded hook heads and the injection molded base plate, wherebythe hook foot of the injection molded hook is pushed out of the firstcavity.

In the apparatus according to the invention, at least one first moldhalf preferentially exhibits a respective first surface on two oppositesides, and at least one second mold half exhibits a respective secondsurface on two opposite sides. This configuration enables the inventiveapparatus to provide a hook-and-loop fastener connector having a highdensity of hooks.

The third and fourth surfaces are preferably planar. This enables theproduction of a hook-and-loop fastener element having a planar baseplate.

The first and second surfaces are preferably planar. This enables asimple design and manufacture of the first and second mold halves andeasy displaceability of the first and second mold halves relative to oneanother.

It is preferential for the second cavities to be formed such that eachof the ends of the hook head forms exhibit the same orientation.

The first and second mold halves are preferably arranged concentricallyto one another, further preferentially circularly concentric to oneanother. The advantage of such a concentric arrangement is that when theconcentric first and second mold halves are removed or expelled by thedisplacement of the concentric first and second mold halves against eachother, there is a relatively even distribution of forces pressing on theinjection molded hook heads or the injection molded base plate.

When the first and second mold halves are arranged circularly concentricto one another, it is then preferential for all the second cavities tobe formed such that all the hook head forms are essentially tangentialto the circular form of the second mold half and each of the ends of thehook head forms exhibit the same orientation. In this context,“essentially tangential” means that the plane within which the hook footand hook head are arranged is perpendicular or respectively at atolerance of ±5° to a contact radius of the second mold half. When afirst mold half has a respective first surface on two opposite sides anda second mold half has a respective second surface on two oppositesides, said respectively same orientation can either be the same oropposite on both opposite sides, preferentially opposite. If theopposite sides of the first mold half and second mold half exhibitrespectively opposite orientations with respect to the hook forms, ahook-and-loop fastener connector is obtained with the inventiveapparatus in which the plurality of circularly concentrically arrangedhooks have the same orientation in a circle to the ends of the hookheads tangential to the circular shape while in a circle adjacent tothis circle of hooks, the ends of the hook heads tangential to thecircular shape exhibit an orientation which is opposite to that of theadjacent circle. This circular concentric arrangement of the hooks, inwhich the hook heads of the adjacent circles each have an oppositetangential orientation to the circular shape, is also referred to hereinas “circularly concentric to each other.” This arrangement enables aparticularly advantageous stable hooking connection to a pile portion.

According to one preferential embodiment, the second mold half is formedin such a way that the hook head is shaped as a double hook head, itshook heads pointing in 180° opposite directions. This has the advantageof being able to form a hook having two hook heads, whereby thestability of the hooking connection is virtually doubled compared tohooks having only one hook head.

The cross section or respectively cross-sectional area of the hook footand/or hook head can in principle be of any shape, for example polygonalsuch as e.g. triangular, rectangular, pentagonal or hexagonal,essentially circular, or a mixed form of polygonal and essentiallycircular, e.g. a polygonal cross section with rounded corners. It ispreferential for the cross section/cross-sectional area of the hook footand/or hook head to be essentially circular. Meant here by “essentiallycircular” is circular, of circular segmented shape or oval, whereby itis preferential for the cross section of the hook foot and/or hook headto be of circular or circular segmented shape. A hook head cross sectionof circular segmented shape can be formed by, for example, the circulararc of the circle segment being formed by the second cavity of thesecond mold half and the circle chord of the circle segment by a planarfirst surface of the first mold half.

The opening formed jointly by the third and fourth surface ispreferentially circular and the third surface forms a circle segment of60-80% of the circular area of the opening and the fourth surface formsa circle segment of 20-40% of the circular area of the opening, underthe condition that the total circular area of the opening amounts to100%. This advantageous configuration of the third and fourth surfacesenables a larger part of the hook foot cross section to be formed in thefirst mold half while the second mold half forms a smaller part of thehook foot cross section.

The dimensions of the hook form defined below are selected in such a waythat an injection molded hook can be easily demolded/removed from thefirst or respectively second mold half without being damaged, e.g. bytearing away the hook head. The following defined hook form dimensionsfurther enable obtaining a hook by injection molding which ensures anadvantageously stable hook-and-loop connection to a pile portion.

The first and second mold half, in particular the first cavity of thefirst mold half and the second cavity of the second mold half, arepreferentially dimensioned such that the circular cross section of thehook foot exhibits a diameter of from 0.3 to 0.8 mm, furtherpreferentially 0.4 to 0.7 mm, particularly preferentially 0.45 to 0.6mm.

It is furthermore preferential for the first and second mold halves tobe dimensioned such that the hook head exhibits a diameter equal to orgreater than the diameter of the hook foot, preferably the hook head isup to 25% greater in diameter than the hook foot, preferentially 4% to22% greater, further preferentially 6 to 18% greater, particularlypreferentially 8 to 12% greater. If the hook head is not of circularcross section but rather circular segmented shape, the diameter of thehook head's cross section of circular segmented shape is then selectedsuch that the hook head's cross section/cross-sectional area of circularsegmented shape is at least equal to or preferentially greater than thecircular cross section/cross-sectional area of the hook foot.

It is furthermore preferential for the first and second mold halves tobe dimensioned such that the hook form is 1.2 to 4 mm in height from thehook foot to the hook head, further preferentially 1.5 to 3 mm,particularly preferentially 1.8 to 2.5 mm. This height from the hookfoot to the hook head is measured vertically from the third and fourthsurfaces to the highest point of the hook head of the hook form.

The further cavity in the form of a base plate of the hook-and-loopfastener connector is preferably circular and exhibits a diameter of 5to 10 cm and a thickness of 1 to 5 mm, further preferentially a diameterof 6 to 8.5 cm and a thickness of 1.5 to 4 mm, and particularlypreferentially a diameter of 6 to 7.5 cm and a thickness of 2 to 3 mm.The thickness of the circular base plate as specified here is understoodto be without the optional fastening means which can be arranged on theside opposite the side with the plurality of hooks.

It is preferential for the hook-and-loop fastener connector to be afastening device for a motor vehicle floor mat. Preferentialconfigurations of a fastening device for a motor vehicle floor mat arediscussed in the description of the hook-and-loop fastener connectoraccording to the invention.

According to one particularly preferential embodiment, an apparatus isprovided for producing a hook-and-loop fastener connector via aninjection molding method, which comprises the following:

An injection mold having a plurality of first and second mold halves,wherein each first mold half exhibits a plurality of first cavities in afirst surface and each second mold half exhibits a plurality of secondcavities in a second surface, and the first and second surfaces faceeach other and contact such that the first and second cavity togetherform an entire cavity in hook form,

wherein the hook form exhibits a hook foot and a hook head, and the hookfoot and hook head are arranged within one plane, wherein the hook footis formed by the first and second cavity and the hook head is formed bythe second cavity,

wherein the injection mold has a longitudinal axis along which thesecond mold halves are displaceable in relation to the first moldhalves,

wherein the first and second surfaces of the plurality of first andsecond mold halves are arranged parallel to each other and parallel tothe longitudinal axis,

characterized in that the plane and the longitudinal axis are angled toone another at an angle a of 5° to 30°, preferentially 10° to 20°,

the second cavity is preferentially dimensioned such that the hook headexhibits a cross section equal to or greater than the cross section ofthe hook foot, and

the first and second mold halves are preferentially arranged circularlyconcentric to one another. The above-cited particularly preferentialembodiment of the inventive apparatus further optionally comprises:

The first mold half exhibiting a third surface and the second mold halfa fourth surface, the third surface being adjacent the first surface andthe fourth surface being adjacent the second surface, whereby the thirdand fourth surface together form an opening constituting the crosssection of the lower end of the hook foot, wherein this opening leads toa further cavity in the form of a base plate of the hook-and-loopfastener connector so that when the injection mold is filled, ahook-and-loop fastener connector having a plurality of hooks formed onthe base plate is obtained,

wherein the third surface is perpendicular to the first surface and thefourth surface is perpendicular to the second surface, and the third andfourth surfaces are planar.

The invention moreover relates to an injection molding method forproducing a hook-and-loop fastener connector using the inventiveapparatus. The advantages of this injection molding method stem from theadvantages of the apparatus as already explained above.

In terms of process parameters such as the temperature(s) for melting astarting plastic and injection molding into the injection mold as wellas in terms of the choice of plastic, the injection molding methodaccording to the invention does not differ from conventional injectionmolding processes. For example, a plastic from the group consisting ofpolyamides, polyalkylenes and thermoplastic copolymers can be selectedas the starting plastic, preferentially the plastic is selected from thepolyamide, polyethylene, polypropylene andacrylonitrile-butadiene-styrene (ABS) group, further preferentiallypolyamide or polyethylene, particularly preferentially polyamide 56. Theprocess temperature(s) is/are selected as a function of the type ofplastic being used.

In the inventive injection molding method, the hook-and-loop fastenerconnector is preferably molded in one piece in the injection mold. Thatmeans that the hook-and-loop fastener connector can be formed in onestep. This has the advantage of further steps not being required inorder to attach the plurality of hooks to a base body, e.g. in the formof a base plate, and/or attach optional fastening means to the basebody.

The method according to the invention preferentially comprises thefollowing steps:

-   -   a) injecting molten plastic into the injection mold;    -   b) cooling the molten plastic in the injection mold until the        plastic is solid;    -   c) longitudinally displacing the second mold halves along the        injection mold toward a base plate of the hook-and-loop fastener        connector on which the hooks are formed in order to remove the        hook feet from the first mold halves.

The inventive apparatus used in the inventive method comprises aninjection mold with first and second mold halves which are designed suchthat the plane within which the hook foot and the hook head of the hookform are arranged and the longitudinal axis of the injection mold areangled to each other. This facilitates demolding or expulsion step c),because the pressure exerted on the hook head by the displacing of thesecond mold halves thereby allows the hook feet to be easily pushed outor removed from the injection mold. Depending on the design of theinjection mold, the injection mold can be opened in the direction of thefurther cavity in the form of a base plate between steps b) and c) inorder to enable the second mold halves to displace toward the base plateof the injection molded hook-and-loop fastener connector. Alternatively,the apparatus or injection mold respectively can comprise a mechanismwhich allows displacement of the second mold halves in step c) withoutthe injection mold needing to be opened prior to step c), e.g. amechanism which enables the injection mold to be opened in the directionof the further cavity in the form of a base plate via displacement ofthe second mold halves in that the second mold halves exert pressure onthe injection molded base plate and the injection mold thus opens, e.g.by means of a spring-loaded mechanism.

The method according to the invention preferably further comprises thefollowing step:

-   -   d) pulling on the base plate of the hook-and-loop fastener        connector so as to pull out the hook heads located in the second        mold halves.

While the hook feet are pushed out or respectively demolded by means ofstep c), step d) serves the demolding of the hook heads. Pulling on thebase plate of the hook-and-loop fastener connector in step d) can beeffected by any suitable means. The crucial advantage with step d) isthat due to the injection mold with first and second mold halvesdesigned such that the plane within which the hook foot and the hookhead of the hook form are arranged and the longitudinal axis of theinjection mold are angled to each other, the hook heads can be easilypulled out of the second mold halves without being damaged in theprocess.

The invention furthermore relates to a hook-and-loop fastener connectorhaving a plurality of hooks arranged on a base plate, whereby the hooksexhibit a hook foot and a hook head and the hook foot and hook head arearranged within one plane, characterized in that the plane and the baseplate are angled to each other at an angle β greater than 90°.Conventional hook-and-loop fastener connectors have hooks which, due totheir manufacturing process, are formed on a base body at a 90° angle.The present inventors have now surprisingly found that an angle greaterthan 90° not only offers advantages relative to the apparatus for themanufacturing and injection molding process but in fact that an anglegreater than 90° also ensures an advantageous, particularly stablehook-and-loop connection to a pile portion.

The hook-and-loop fastener connector can preferably be obtained via theabove-described inventive method. Doing so enables producing thehook-and-loop fastener connector with the previously cited advantages aswere noted in conjunction with the inventive apparatus and inventivemethod.

The angle β between the imaginary plane, within which the hook foot andhook head are arranged, and the base plate of the inventivehook-and-loop fastener connector corresponds to the angle a between theplane and the longitudinal axis of the injection mold of the inventiveapparatus when the hook-and-loop fastener connector according to theinvention is produced by way of the inventive method. For example, angleβ is equal to angle a plus 90° when the third surface is perpendicularto the first surface in the first mold half and the fourth surface isperpendicular to the second surface in the second mold half; i.e. atangle α=15°, then angle β=15°30 90°=105°. Thus, the angling at an angleβ of greater than 90° in the inventive hook-and-loop fastener connectorshows that it was produced by means of the inventive method or inventiveapparatus respectively.

It is preferential for the plane and the base plate to be angled to oneanother at an angle β greater than 90° to 130°, further preferentially95° to 120°, and particularly preferentially 100° to 110° in theinventive hook-and-loop fastener connector. It was surprisingly foundthat an angle β of 95° to 120°, and particularly an angle of 100° to110°, is particularly advantageous with respect to the stability of thehook-and-loop connection to a pile portion. The angles specified inconjunction with the angled arrangement of the plane and the base plateto one another also include negative angles; i.e. angles that are angledmore than −90° to −130° to each other, preferentially more than −95° to−120°, and particularly preferentially more than −100° to −110°. Theplurality of hooks arranged on the base plate can thereby also be formedin opposite directions, thus once at a positive angle and once at anegative angle.

The inventive hook-and-loop fastener connector is in principle suitablefor any application such as, for example, in the leisure sector, inhouseholds or in industrial settings, e.g. the automotive sector. Thehook-and-loop fastener connector can to that end be of any form suitablefor the desired application; particularly the shape and the dimensioningof the hook as well as the shape of the base plate are suitably selectedaccordingly, and fastening means optionally attached to the base platecan also be suitably selected depending on the area of application.

The plurality of hooks can be circularly concentrically arranged on thebase plate in the inventive hook-and-loop fastener connector,preferentially circularly concentric to each other.

The inventive hook-and-loop fastener connector is preferably a fasteningdevice for a motor vehicle floor mat, the preferential embodiment ofwhich is explained below.

The hook-and-loop fastener connector is preferably a fastening devicefor a motor vehicle floor mat which comprises fastening meanspreferentially on the side of the base plate opposite the side with theplurality of hooks for fixing the base plate to the floor of a motorvehicle's interior, whereby the base plate, the plurality of hooks andthe fastening means are formed in one piece. The one-piece formation ofthe hook-and-loop fastener connector has the advantage of the pluralityof the hooks as well as the fastening means being an integral part ofthe hook-and-loop fastener connector, whereby both the hookingconnection to a pile portion as well as the fixing to the motorvehicle's interior floor is considerably more stable than is the casewith a hook-and-loop fastener connector in which the plurality of hooksand/or the fastening means are separate components subsequently attachedto the base plate.

The fastening means can in principle be of any form as long as it issuitable for affixing the base plate to the floor of a motor vehicle'sinterior. The fastening means is preferentially in the form of a screwor a T-shaped anchoring element.

The dimensions of the hook, base plate and optional fastening means ofthe hook-and-loop fastener connector according to the invention can beappropriately selected depending on the area of application.

The hook-and-loop fastener connector preferably exhibits hooks having ahook foot of circular cross section at a diameter of 0.3 to 0.8 mm,further preferentially 0.4 to 0.7 mm, particularly preferentially 0.45to 0.6 mm. The hook head of the hook of the hook-and-loop fastenerconnector is furthermore preferably designed such that the hook head hasa diameter equal to or greater than the diameter of the hook foot,preferably the hook head is up to 25% greater in diameter than the hookfoot, preferentially 4% to 22% greater, further preferentially 6 to 18%greater, particularly preferentially 8 to 12% greater. If the hook headis not of circular cross section but rather circular segmented shape,the diameter of the hook head's cross section of circular segmentedshape is then selected such that the hook head's crosssection/cross-sectional area of circular segmented shape is at leastequal to or preferentially greater than the circular crosssection/cross-sectional area of the hook foot. This dimensioning of thehook foot and/or hook head contributes to a stable hook-and-loopconnection to a pile portion. Particularly the dimensioning of the hookhead to the same or larger diameter/cross section as the hook footcontributes to a particularly stable hook-and-loop connection to a pileportion. Because if one tries to disengage a hook-and-loop/pile portionconnection, a higher pull-off force is required for the hook headbecause, among other things, the hook head is more stable due to theadvantageous dimensioning and tears away from the hook foot much lesseasily than a hook head having a smaller diameter than the hook foot.

The hooks of the hook-and-loop fastener connector are preferably 1.2 to4 mm in height from the hook foot to the hook head, preferentially 1.5to 3 mm, particularly preferentially 1.8 to 2.5 mm. This height from thehook foot to the hook head is measured vertically from the base plate tothe highest point of the hook head.

It is preferential for the base plate of the hook-and-loop fastenerconnector to be circular and exhibdeit a diameter of 5 to 10 cm and athickness of 1 to 5 mm, preferentially a diameter of 6 to 8.5 cm and athickness of 1.5 to 4 mm, particularly preferentially a diameter of 6 to7.5 cm and a thickness of 2 to 3 mm. The aforementioned thickness of thebase plate only relates to the base plate itself, meaning that theplurality of hooks arranged thereon as well as the optional fasteningmeans do not factor into this height. This preferential dimensioning ofthe base plate ensures advantageous stability for the base plate,particularly for the intended application as a fastening device for amotor vehicle floor mat.

It is preferential for the fastening means to be 0.4 to 3 cm in lengthmeasured from the base plate, further preferentially 0.8 to 2.4 cm,particularly preferentially 1.2 to 1.8 cm. This thereby ensures anadvantageously stable fixing of the inventive hook-and-loop fastenerconnector, e.g. to the floor of a motor vehicle's interior.

The hook head is preferably designed as a double hook head, its hookheads pointing in 180° opposite directions. This has the advantage ofvirtually doubling the stability of the hooking connection compared tohooks having only one hook head.

Provided according to one particularly preferential embodiment is ahook-and-loop fastener connector having a plurality of hooks arranged ona base plate, wherein the hooks exhibit a hook foot and a hook head andthe hook foot and hook head are arranged within one plane, characterizedin that the plane and the base plate are angled to each other at anangle β of 95° to 120°, preferentially 100° to 110°; the hookspreferentially exhibit a hook head having a diameter equal to or greaterthan the diameter of the hook foot, and the plurality of hooks arepreferentially arranged circularly concentrically on the base plate. Thefollowing will reference the accompanying schematic drawings indescribing the invention in greater detail on the basis of an exemplaryembodiment. Shown are:

FIG. 1: a top view from diagonally above onto the plurality of first andsecond mold halves of the inventive apparatus, wherein the first andsecond mold halves here are displaced relative to one another along thelongitudinal axis of the injection mold;

FIG. 2: a half cross-sectional view of the injection mold of theinventive apparatus, whereby in contrast to FIG. 1, the first and secondsurfaces face each other and contact such that the first and secondcavity together form an entire cavity in hook form. The dashed lineindicates where the cross section of the injection mold washalved—mirroring the half cross-sectional view against the dashed lineprovides the full cross-sectional view of the injection mold;

FIG. 3: a detail view of the encircled section A shown in FIG. 2;

FIG. 4: side views of schematically depicted hook forms;

FIG. 5 two side views of a particularly preferential hook formed by anentire cavity in hook form as formed by the first and second cavitytogether;

FIG. 6: a side view of a preferential hook having a double hook head;

FIG. 7: a top view from diagonally above onto the hook-and-loop disk ofa preferential hook-and-loop fastener connector; and

FIG. 8: a top view from diagonally above onto the lower portion of thepreferential hook-and-loop fastener connector.

FIG. 1 shows a preferential embodiment of the inventive apparatusdepicting a plurality of first mold halves 1 and second mold halves 2which are arranged circularly concentric to one another. The second moldhalves 2 here are displaced along the longitudinal axis 12 of theinjection mold 11 in relation to the first mold halves; i.e. indemolding or respectively expulsion position. To produce thehook-and-loop fastener connector, the first mold halves 1 and secondmold halves 2 are arranged in such a manner (not shown in FIG. 1) thatthe plurality of first cavities 3 in a first surface 4 of the first moldhalf 1 and the plurality of second cavities 5 in a second surface 6 ofthe second mold half 2 face each other and contact so that the firstcavity 3 and second cavity 5 together form an entire cavity in hook form7. The hook foot 8 here is formed by the first cavity 3 and secondcavity 5 and the hook head 9 is formed by the second cavity 5.

It is evident from FIGS. 2 and 3 how the (imaginary) plane 10 withinwhich the hook foot 8 and hook head 9 are arranged and the longitudinalaxis 12 of the injection mold 11 are angled to one another, in thisexample case at an angle a of 15° . FIG. 3 depicts the plane 10 as asimple line because plane 10 is being viewed from the side here. In theapparatus depicted here, the first mold half 1 exhibits a third surface13 and the second mold half 2 a fourth surface 14, the third surface 13being adjacent the first surface 4 and the fourth surface 14 beingadjacent the second surface 6. The third surface 13 and fourth surface14 together form an opening which constitutes the cross section of thelower end of the hook foot 8. This opening leads to a further cavity 15in the form of a base plate 16 of the hook-and-loop fastener connectorso that when the injection mold is filled, a hook-and-loop fastenerconnector having a plurality of hooks formed on the base plate isobtained. The further cavity 15 in the form of a base plate 16 of thehook-and-loop fastener connector shown here is furthermore configuredwith a cavity in the form of a fastening means 19. Due to the angling ofthe plane 10 and longitudinal axis 12 to one another 12, hooks 7 areprovided on the base plate during injection molding at an angle β. Sincethe third surface 13 is perpendicular to the first surface 4 and thefourth surface 14 is perpendicular to the second surface 6 in thepresent example, angle β here is equal to angle a plus 90°, thus angleβ=105°.

FIG. 4 shows side views of schematically depicted hook forms,specifically from left to right: hook forms 7 with hook heads 9 insemicircular form, ⅔ semicircular form, angled in an inverted V shapeand in an angular inverted U shape. The dashed line shows the schematicseparation between hook head 9 and hook foot 8. In semicircular orcircular form, the hook head 9 begins (and the hook foot 8 ends) at thecircular curvature of the hook head. In the inverted V shape and angularU shape, the hook foot 8 ends and the hook head 9 begins at the pointwhere the dashed line, running from the end of the hook head,perpendicularly intersects the hook foot. However, the separationbetween hook head and hook foot shown here is purely schematic. Becausein three-dimensional form, part of the hook foot can fall below orexceed the height of the separation point along the longitudinaldirection of the hook foot shown in FIG. 4.

FIG. 5 shows a preferential hook (form) 7 having a hook foot 8 and ahook head 9, and that in two side views of the hook (form) 7. The hookfoot 8 here exhibits a circular cross section and the hook head 9exhibits an essentially circular cross section of circular segmentedshape. Evident from the hook form on the left is that a part of the hookfoot 8 formed by the first mold half extends beyond the point at whichthe hook head 9 begins to curve.

FIG. 6 shows an example of a hook (form) 7 having a double hook head 17.

FIG. 7 shows a preferential embodiment of the hook-and-loop fastenerconnector 18 in the form of a fastening device for a motor vehicle floormat, and specifically its upper side exhibiting a plurality of hooks 7on the base plate 16. The hooks 7 here are arranged in a circularconcentric manner, whereby the orientation of the hook head forms isopposite from one concentric ring of hooks 7 to the adjacent concentricring of hooks 7; i.e. the hooks are arranged against each other in acircle.

FIG. 8 shows the underside of the hook-and-loop fastener connector 18shown in FIG. 7 which comprises a fastening means 19 as a T-shapedanchoring element.

LIST OF REFERENCE NUMERALS

-   -   1 first mold half    -   2 second mold half    -   3 first cavity    -   4 first surface of first mold half    -   5 second cavity    -   6 second surface of second mold half    -   7 hook (form)    -   8 hook foot    -   9 hook head    -   10 plane within which the hook foot and hook head are arranged    -   11 injection mold    -   12 longitudinal axis    -   13 third surface of first mold half    -   14 fourth surface of second mold half    -   15 further cavity in the form of a base plate of the        hook-and-loop fastener connector    -   16 base plate of the hook-and-loop fastener connector    -   17 double hook head    -   18 hook-and-loop fastener connector in the form of a fastening        device for a motor vehicle floor mat    -   19 fastening means of base plate 16    -   A detail from FIG. 2    -   α angle between plane 10 and longitudinal axis 12    -   β angle between plane 10 and base plate 16

1. An apparatus for producing a hook-and-loop fastener connector (18)via an injection molding method, which comprises: an injection mold (11)having a plurality of first and second mold halves (1;2), wherein eachfirst mold half (1) exhibits a plurality of first cavities (3) in afirst surface (4) and each second mold half (2) exhibits a plurality ofsecond cavities (5) in a second surface (6), and the first and secondsurfaces (4;6) face each other and contact such that the first andsecond cavity (3; 5) together form an entire cavity in hook form,wherein the hook form (7) exhibits a hook foot (8) and a hook head (9),and the hook foot (8) and hook head (9) are arranged within one plane,wherein the hook foot (8) is formed at least by the first cavity (3) andthe hook head (9) is formed at least by the second cavity (5), whereinthe injection mold (11) has a longitudinal axis (12) along which thesecond mold halves (2) are displaceable in relation to the first moldhalves (1), characterized in that the plane (10) and the longitudinalaxis (12) are angled to one another.
 2. The apparatus according to claim1, which has at least one of the following features: the plane (10) andthe longitudinal axis (12) are angled to each other at an angle (α) ofup to 40°, preferentially 5° to 30°, particularly preferentially 10° to20°; the first and second surfaces (4;6) of the plurality of first andsecond mold halves (1;2) are arranged parallel to each other,preferentially parallel to the longitudinal axis (12); the hook foot (8)is formed by the first and second cavity (3;5) and the hook head (9) isformed by the second cavity (5); the second cavity (5) is dimensionedsuch that the hook head (9) exhibits a cross section equal to or greaterthan the cross section of the hook foot (8); at least one first moldhalf (1) exhibits a respective first surface (4) on two opposite sidesand at least one second mold half (2) exhibits a respective secondsurface (6) on two opposite sides; the second mold half (2) isconfigured such that the hook head (9) is shaped as a double hook head(17), its hook heads pointing in 180° opposite directions; the crosssection of the hook foot (8) and/or hook head (9) is essentiallycircular.
 3. The apparatus according to claim 1 or 2, wherein the firstmold half (1) exhibits a third surface (13) and the second mold half (2)exhibits a fourth surface (14), and the third surface (13) is adjacentthe first surface (4) and the fourth surface (14) is adjacent the secondsurface (6), wherein the third and fourth surface (13;14) together forman opening constituting the cross section of the lower end of the hookfoot (8); this opening preferentially leading to a further cavity (15)in the form of a base plate (16) of the hook-and-loop fastener connector(18) so that when the injection mold is filled, the hook-and-loopfastener connector (18) with a plurality of hooks (7) formed on the baseplate (16) is obtained.
 4. The apparatus according to claim 3 having atleast one of the following features: the third surface (13) isperpendicular to the first surface (4) and the fourth surface (14) isperpendicular to the second surface (6); the second mold halves (2) aredisplaceable in the direction of the further cavity (15) in the form ofa base plate (16) of the hook-and-loop fastener connector (18) while thefirst mold halves (1) maintain their position; the third and fourthsurfaces (13;14) are planar.
 5. The apparatus according to one of thepreceding claims, wherein the first and second surfaces (4; 6) areplanar and the second cavities (5) are preferentially formed such thateach of the ends of the hook head forms (9) exhibit the sameorientation.
 6. The apparatus according to one of claims 1 to 4, whereinthe first and second surfaces (1; 2) are arranged concentrically to oneanother.
 7. The apparatus according to claim 6, wherein the first andsecond mold halves (1; 2) are arranged circularly concentric to oneanother and all the second cavities (5) are preferentially formed suchthat all the hook head forms (9) are essentially tangential to thecircular form of the second mold half (2) and each of the ends of thehook head forms (9) exhibit the same orientation.
 8. The apparatusaccording to one of claims 3 to 7, wherein the opening is circular andthe third surface (13) forms a circle segment of 60-80% of the circulararea of the opening and the fourth surface (14) forms a circle segmentof 20-40% of the circular area of the opening, under the condition thatthe total circular area of the opening amounts to 100%; and/or the firstand second mold half (1; 2) are dimensioned such that the hook head (9)exhibits a diameter equal to or greater than the diameter of the hookfoot (8), wherein the hook head (9) is preferably up to 25% greater indiameter than the hook foot (8), further preferentially 4% to 22%greater, even further preferentially 6 to 18% greater, particularlypreferentially 8 to 12% greater.
 9. An injection molding method forproducing a hook-and-loop fastener connector (18) using an apparatusaccording to one of claims 1 to
 8. 10. The injection molding methodaccording to claim 9, wherein the hook-and-loop fastener connector (18)is molded in one piece in the injection mold (11).
 11. The injectionmolding method according to claim 9 or 10, comprising the followingsteps a) to c), and optionally step d): a) injecting molten plastic intothe injection mold (11); b) cooling the molten plastic in the injectionmold (11) until the plastic is solid; and; c) longitudinally displacingthe second mold halves (2) along the injection mold (11) toward the baseplate (16) of the hook-and-loop fastener connector (18) on which thehooks (7) are formed in order to remove the hook feet (8) from the firstmold halves (1); d) pulling on the base plate (16) of the hook-and-loopfastener connector (18) so as to pull out the hook heads (9) located inthe second mold halves (2).
 12. A hook-and-loop fastener connector (18)having a plurality of hooks (7) arranged on a base plate (16), whereinthe hooks (7) exhibit a hook foot (8) and a hook head (9), and the hookfoot (8) and hook head (9) are arranged within one plane (10),characterized in that the plane (10) and the base plate (16) are angledto each other at an angle (62 ) greater than 90°.
 13. The hook-and-loopfastener connector (18) according to claim 12, wherein the plane (10)and the base plate (16) are angled to one another at an angle (β)greater than 90° to 130°, further preferentially 95° to 120°, andparticularly preferentially 100° to 110°; and/or the hook-and-loopfastener connector (18) is obtainable by a method according to one ofclaims 9 to
 11. 14. The hook-and-loop fastener connector (18) accordingto claim 12 or 13, wherein the hook-and-loop fastener connector (18) isa fastening device for a motor vehicle floor mat which has at least oneof the following features: a fastening means (19) on the side of thebase plate (16) opposite the side with the plurality of hooks (7),wherein the fastening means (19) serves to fix the base plate (16) tothe floor of a motor vehicle's interior, and the base plate (16), theplurality of hooks (7) and the fastening means (19) are formed in onepiece; a fastening means (19) in the form of a screw or a T-shapedanchoring element; a fastening means (19) of 0.4 to 3 cm in lengthmeasured from the base plate, preferentially 0.8 to 2.4 cm, particularlypreferentially 1.2 to 1.8 cm.
 15. The hook-and-loop fastener connector(18) according to one of claims 12 to 14 which comprises at least one ofthe following features: the plurality of hooks (7) are arrangedcircularly concentrically on the base plate; each hook (7) exhibits ahook foot (8) of circular cross section at a diameter of 0.3 to 0.8 mm,preferentially 0.4 to 0.7 mm, particularly preferentially 0.45 to 0.6mm; each hook (7) exhibits a hook head (9) having a diameter equal to orgreater than the diameter of the hook foot (8), preferably up to 25%greater in diameter than the hook foot, further preferentially 4% to 22%greater, even further preferentially 6 to 18% greater, particularlypreferentially 8 to 12% greater; each hook (7) is 1.2 to 4 mm in heightfrom the hook foot (8) to the hook head (9), preferentially 1.5 to 3 mm,particularly preferentially 1.8 to 2.5 mm; the base plate (16) of thehook-and-loop fastener connector is circular and exhibits a diameter of5 to 10 cm and a thickness of 1 to 5 mm, preferentially a diameter of 6to 8.5 cm and a thickness of 1.5 to 4 mm, particularly preferentially adiameter of 6 to 7.5 cm and a thickness of 2 to 3 mm.